Laser-Welded Connector Assembly for Precise Signal Contact Alignment
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Solution Overview
Problem
Existing connector assemblies for high-speed applications, such as the H-MTD system, face challenges in achieving accurate and secure connections between male and female signal contacts and between signal contacts and cable conductors, while maintaining signal integrity and mechanical stability.
Innovation Solution
The connector assembly comprises an elongated inner signal contact with a tube-like connection portion and a funnel-shaped end section, embedded in an insulating element with aligned welding openings, allowing for precise alignment and secure connection through laser welding, and featuring a design that ensures correct guidance and secure connection of male and female signal contacts and cable conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional connector assembly methods are used, then assembly is simpler, but connection accuracy and data transmission reliability deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-defining the positions of welding openings in the insulating element and alignment features on signal contacts before assembly. The insulating element includes pre-formed welding openings that guide the alignment of multiple components, ensuring precise positioning during assembly without requiring complex adjustment mechanisms during the assembly process itself.
Solution Approach 2:
The patent replaces traditional mechanical alignment and connection methods with laser welding technology. Instead of relying on mechanical tolerances and manual alignment, the invention uses laser welding to create precise, permanent connections between conductors, signal contacts, and the insulating element, significantly improving connection accuracy while maintaining assembly efficiency.
2Volume of moving object
If connector dimensions are reduced for miniaturization, then device size decreases, but mechanical stability and connection security worsen
Solution Approach 1:
The patent employs composite material structures by combining the insulating element with integrated reinforcement features. The insulating element is constructed as a composite structure that provides both electrical insulation and mechanical support, allowing the connector to maintain mechanical stability and connection security even as overall dimensions are reduced for miniaturization.
3Reliability
If precise alignment features are added to ensure correct guidance, then connection reliability improves, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating alignment features directly into the insulating element and signal contact structures themselves, rather than adding separate alignment mechanisms. The welding openings and alignment features are formed as integral parts of the components, combining multiple functions (alignment, insulation, connection) into unified structures that improve reliability without significantly increasing overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a more accurate and secure connection, ensuring high data transmission reliability and mechanical stability, while allowing for miniaturization and optimized dimensions for improved data transmission performance.
Implementation Method 1
The first welding opening and the at least one second welding opening are aligned in an assembled state of the connector assembly... allowing for precise alignment and secure connection through laser welding
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
A connector assembly includes at least one elongated inner signal contact defining an axial direction and having a tube-like connection portion, wherein the tube-like connection portion defines a first welding opening. The connector assembly further includes an insulating element including a first insulating part and a second insulating part, wherein the first insulating part defines at least one elongated cavity designed to accommodate the at least one elongated inner signal contact and the second insulating part includes at least one second welding opening. The first welding opening and the at least one second welding opening are aligned in an assembled state of the connector assembly.